The Iron Age 1930-06-19: Vol 125 Iss 25

AGE New York, June 19, 1930 ESTABLISHED 1855 Expands Gasoline Pump Output From 500 Units Day PRENTISS* gasoline filling station has created con- stantly growing demand for motor car servicing equipment various types, one the most im- portant which the gasoline-dispensing unit. quite commonly used dispensing unit consists three main parts: pump, motor and meter. The meter has dial that registers the amount gasoline de- livered, the dial being located the top the hous- ing which the mechanism inclosed. manufacturing unit for making pumps for meter well visible gas-dispensing systems production basis was recently installed the Ferro Machine Foundry Co., Cleveland. Starting manu- facturing the pumps the rate ten units per day about year ago, this company, with the expansion its equipment and with the arrangement machinery for the economic routing work and provision various types conveyors for handling work process, including assembly, now producing 500 pumps 9-hr. day. The machine tool equipment arranged according op- eration sequence and the pieces for the most part move from machine machine roller conveyors, finally gether central point the side the assembly line which the units are put together con- veyor track. sev- eral points there double deck section roller table, the upper section which *Resident editor THE article. IRON AGE Cleveland. UTOMATIC and semi-automatic machine tools, multiple-operation handling the work process, including assembly, and arrangement machines for economical rout- ing were brought into service stepping-up the for the Ferro Machine Foundry Co.’s gasoline pump ca- pacity from 500 units day. Steps machining, assembling and inspecting these parts, well the arrangement con- veyors which bring all parts together the proper place the assembly line, are outlined this 1805 employed for the storage parts process. The pump unit produced the Ferro plant in- cludes the pump and bracket, the bottom which the pump attached. Pumps are built the com- pany standard equipment for most the leading manufacturers gasoline-dispensing systems and these complete the assembly the operating unit mounting motor above the bracket and adding the metering equipment. The pump rotary type and driven through flexible coupling and stuffing box located within the bracket. Pumping action secured two eccentric cams that float freely stainless steel shaft. This method pumping, combined with spring-controlled by-pass valve as- sures, stated, rapid uniform non- pulsating and non-agitating flow. Rapid flow has become important factor the gasoline-dispensing system because customers demand quick service. The main parts the pump are made and the assembling, testing and shipping are done the ground floor the build- ing used for this department. The smaller parts are manufactured the two upper floors. The pump made three main castings, the body and top and bottom cover. The castings for these, well all other parts pump, are made the com- pany’s foundry automobile cylinder iron, containing ap- proximately per steel. castings are annealed avoid size changes conveyors for VOL. 125, No. 4 | | caused warping after machining. machine work has held close limits. Pro- duction has been speeded the use improved automatic and semi-automatic multiple operations. Much the machinery and Machine Work Starts With Milling Machine work starts with milling two faces the body and one each cover horizontal milling machine. Mounted the table are jigs that hold and four pieces are clamped each jig, two bodies the top and cover each side. The machine has eight cutters, two cuts being taken each piece, first roughing and then finishing cut. Castings for pumps pieces are milled per hour. This machine operates day and night shift. the work, the milling machine the pieces roller From the milling machine the lle separates into two conveyor, which lines. The Iron Age, June 19, 1930 UMP Having Been Milled the Ma- chine Shown the Right, Are Carried Roller Conveyors for Successive Oper- ations. Rough and semi-finished boring done the ma- chine the fore- ground bodies move along one line where they are first rough and semi-finished bored. Then three cuts are made hydraulic broaching machine for the two blades and rocker slot. Five holes are then drilled each side, two pieces time, multiple drilling ma- chine. The top holes are drilled and hole for pipe tap drilled right angles the bore. Then rocker plug hole drilled, reamed and tapped. After this the two faces the body are ground Blanchard surface grinder, these faces being held within 0.001-in. limits. The final operation finish- reaming the bore two-spindle vertical boring machine, two pieces being set the machine while two others are being reamed. From here the bodies the inspection bench and the assembly storage racks. The covers after face milling are ground the surface grinder, drilled and reamed, after which they ASSEMBLY the Bottom Cover Car- Track That Has Air-Operated Section Each Fnd. The carriage when unloaded lowered moves the load- ing end ——_— = ACHINES the Cam De- partment Are Ar- ranged for Succes- sive Operations, the Pieces Moving from Machine Machine Roller Con- veyor. Finished cams are inspected the bench the right battery six automatic machines. Two these bore, ream and face by-pass hole and two bore, face and lap strainer hole the bottom cover; the other two bore, ream and lap packing nut boss and shaft hole the top cover. Then the two covers multiple drilling machines, where five stud holes are drilled each piece and three bracket holes are drilled the top cover, holes time. Several operations follow, including spot facing, drilling and tapping, tapping pipe hole the bottom cover radial drill, pressing bushings and facing three bracket bosses the top cover. The top covers are then spray washed. The bottom covers after having seat pressed air press move subassembly line for the by- pass which built into the pump. There are two ma- chines this assembly line, one for line reaming the valve seat and the second, three-spindle lap- Final As- sembly Line the Left. The assembling carriages that move along the conveyor track and, when un- loaded, are carried back the starting end the power- driven veyor beneath the assembly ping machine. The cover cleaned after the machine operations and bronze valve put in. spring inserted hold the valve place. This set through adjusting screw lb. pressure. Finally cover cap put on. The subassembling and two machine operations are done conveyor track approximately ft. long. This consists steel frame the working height the machines and four carriages that slide along the conveyor. Integral with the carriage are three fixtures for holding the work. each end the track lift section operated overhead air hoist. When the assembled pieces are removed the air hoist lowers the carriage near the floor and the car- riage slides gravity the loading end the con- veyor track where the second hoist raises level the track and reloaded. After the subassembly the bottom cover goes The Iron Age, June 19, 1930—1807 inspection bench, where the valves are inspected for leaks, and from there diamond boring ma- chine where shaft hole bored both the top and bottom covers. Limits 0.0002 in. plus minus are maintained this operation. Then the covers are washed and finally steel bins which all parts are stored the side the assembly con- veyor. Cams Ground Close Limits Cams are made round cold rolled steel sawed from the bar, then faced and reamed and 15/16-in. hole countersunk the rate per hr. automatic machine. Then 3/16-in. key- way broached, two time, after which the out- side diameter faced stub lathe. The pieces move from machine machine for successive opera- tions tote boxes roller conveyor. They are 0.008 in. for grinding, after which horizontal milling machine cuts six keyways the end the shaft. The shafts are hardened oil-fired furnace, quenched 1750 deg. Fahr. and drawn, being held Rockwell hardness 39. Following heat treatment they are straightened, ground all dimensions and finally lapped secure smooth surface. Then they are inspected and the shafts and cams are assembled and the assembly line. Blades are made chilled cast iron 1/32-in. over- size allow surplus material for grinding and are ground within 0.0005 in. limits. They are held Rockwell hardness 60. The sides the cast iron brackets are bored and faced one operation horizontal boring mill. Then three faces are drilled, two ends and one and the bracket ready for assembly. carburized after machining rotary-type gas fur- nace which they are kept five hr. 1750 deg. Fahr. and then quenched. the cams 60. The Rockwell hardness After carburizing the two faces are ground surface grinder, time, and the bore ground automatic internal grinder, being held within 0.0005 in. limits. Then the outside di- ameter ground battery external grinders, two separate grinding operations being required, one for grinding the diameter and the other for grinding the eccentric. amplifying instrument used for checking the cams for size after grinding. held within 0.0005 in. They are limits the outer surface. Then they are de-magnetized. Making Shafts and Blades The shafts are made No. stainless steel, which comes sawed length. Three diameters are turned and three necking operations formed two automatic machines, one machine for roughing and the other for finishing cuts. Then automatic machine finishes the three diameters within 1808—The Iron Age, June 19, 1930 ESTED Pumps, Hung Over- head Conveyors, Move Where the Bracket and Some Other Parts Are Added. The unit then goes spray paint booth shown the background. After tion they are packed the containers the foreground The final assembly track, which located along the outer wall, approximately ft. long. Assembling done carriage mounted casters and equipped with cradle that swings pivot. When as- sembler finishes his operation pushes the carriage along the next assembly station. This conveyor track also has lift mechanism either end for han- dling the carriages but differs from the sub-assembly conveyor that the carriage instead returning gravity the return track just above the floor moved back the loading end chain-type con- veyor. When unloaded air hoist drops the car- riage the return track and pushed forward short distance point where the conveyor grips the carriage. When reaches the loading end the second hoist raises level with the assembling track. Parts are given final washing hot soda solu- tion washing machine located the head the assembly line. After washing they are stored bins along the line. Assembly starts with screwing the top cover the body, being located within 0.001 in. limits expanding bushing, after which the cover doweled the body. The assembly then rolled over the pivot, the bottom cover gasket shellacked and the bottom cover loosely bolted place. Similar accuracy locating the bottom cover main- tained order assure that the three members are proper alinement. Then the bottom cover doweled and bolted place, after which the top cover re- moved. The shellac washed out with alcohol and the part dried air blast. double check made with measuring instruments separators and blades. After the first checking they are washed kerosene, blown dry and then assembled the pump. Then the second measuring instrument set the body and readings are again taken that must check with the first readings. The distance between the top the cams and the top cover held within 0.0003 in. limits order assure the proper pumpage. This ac- complished the use from one three gaskets. Several small holes are drilled during assembly operations the two single-spindle drilling machines located the line. After the interior mechanism place and the gaskets are put on, the top cover finally bolted with electric nut driver, the pump packed and the packing put place. Finally strainer assembled the bottom cover and test fitting put on. Then the body leaves the assembly line and goes the test rack. Thirteen men ployed the assembly line and the pumps are com- pletely assembled the rate units hour. Testing starts with suction test under 12-ft. lift, after which there by-pass pressure test lb. pressure. Finally gallonage test made with stop watch see that the specified pumpage gal. per min. maintained. the same time the amperage checked. this runs too high, indi- cates tightness somewhere the pump. Five tiers roller type racks are located the side the test rack. The top rack for storage, the bottom rack for pumps that leak need repairs, two others for pumps tested after the test fit- tings are put and the fifth return rack after testing. The final test air test for leaks; this the pumps are subjected 60-lb. pressure when submerged water. After this test the pump hung hook overhead trolley which goes bench where filled with oil, thread protectors and couplings are put and finally the bracket affixed. Then the pump washed with gasoline and hung back the overhead trolley which carried into booth, where spray painted, after which given final inspection rotating the working mechanism. The pumps are then packed for shipment. Annealing Steel Chains research into the properties steel hoisting chain, especially affected fatigue, “surface impacting” and annealing, progress Carnegie Institute Technology, Pittsburgh, under the direction Prof. Thomas, and sponsored the American Society Safety Engineers. Special machines have been con- structed test complete chain, rather than sample cut from individual link. During the last two years number runs were made fatigue machine, but the results were erratic the conclusions drawn from arithmetical averages are open suspicion. Tests %-in. hand-welded steel chain, tested under repeating load 3500 are follows: (averages are about specimens) Breaking Load Short Lengths Taken From Breaking Chain After Condition Load Repetitions Fatigue Chain Tension Failure Failure Chain purchased..... 10,300 416,000 9,850 New chain, annealed min. 1500 deg. New chain, loaded 100,000 times to 3500 Ib., then annealed above..... 117,000 includ- ing the 100,- nary load- ings) These results seem contradict the usual understand- ing that annealing overstressed chain will cure any damage which has been acquired normal rough ser- vice—at least far steel chain concerned. Welded Alloy Steel Drum Under High Test Pressure prove the constructive strength, mas- sive reaction chamber welded auto- matic electric methods Smith Corporation, Milwaukee, was tested under hydraulic pressure 10,000 per sq. in. This thought the record test pressure for welded vessels. The vessel also notable for being made in. slabs chrome- vanadium steel; ft. long and in. inside diameter. The cylinder operate 5000 per sq. in., and the testing procedure was specified include repeated stressing, hammering when carrying 8000 per sq. in. pressure, and final proof test 10,000 per sq. in. scaling occurred the lime wash placed critical areas, nor did liquid volume read- ings show any permanent enlargement the cylinder. The Iron Age, June 19, = | ™~, ae 7 4 — — Combination Different Types not surprising find that company manu- facturing conveying machinery, cranes and power transmission equipment has studied its own han- dling operations. The Link-Belt Co., Chicago, has large plants and warehouses scattered throughout the country. These employ all types mechanical handling devices, many which the company does not manufacture. the Chicago plant are two lustrations the coor- dinating different types handling de- vices lowest over-all cost for single operation. this company examine each operation, not for- getting its relation other operations the plant, and secure equipment which will provide the great- est over-all economy. Several years ago was de- cided that cupola charging practiced was expen- sive operation, the cost which could reduced through introduction the proper type handling equipment. Charging was then done hand method which still prevails many foundries with 1810—The Iron Age, June 19, 1930 HAT materials handling properly involves use varying types coordinated appa- ratus shown the experience leading manufacturer mechanical handling machin- ery, which utilizes different types equip- ment its own manufacturing operations. Electric trucks and overhead magnet crane combine lower cupola charging costs, while two different types cranes—one truck —are used for yard handling. weekly output 200 tons. With labor hour, the direct labor costs found for this operation are shown the table page 1812. Not only did this cost appear high, but during hot weather the limit endurance for man doing this work was about hr. and the labor cost and turnover were cor- respondingly higher. Study the problem in- dicated that one type mechanical handling would completely solve the problem. The proper solution seemed found the combina- tion gantry crane equipped with magnet and electric indus- trial truck for the charg- ing operation. Changes made the charging floor placed storage bins within reach the magnet crane and the truck. The crane now unloads pig iron and scrap iron, ar- riving cars, and deposits proper bins the charging floor. large amount scrap, however, found various locations throughout the plant. This was factor considered the time electric truck was chosen assist charging. The local plant scrap now collected the electric truck from various places about the plant and brought via IG. Scrap Iron Loaded Skid Boxes Magnet Crane and Electric Trucks Equipped with Scales. The load trimmed exact weight before de- livery cupola *Secretary, Industrial Truck Association, New York ~ elevator the charging floor level. Coke bins are lo- cated ground level also and this material han- dled skid boxes means the electric lift truck. the total tonnage brought the charging floor, the trucks handle about per cent and the crane per cent. While the actual charging the cupolas requires the use only one truck and, fact, was carried for two years single truck, two are regularly em- ployed. together with third lift truck, serve the cupolas, for, addition the actual charging, there large amount col- lecting and transporting work for them do. The additional truck interesting example stand-by equipment which can used emergency, and yet the same time gainfully em- ployed when not needed for the chief operation (see Fig. 4). Box-type skids high legs and open one end are used for charging purposes. eliminate all hand labor the magnet crane loads these boxes approx- DIRECT LABOR COST PER CHARGE Including Cost Truck IG. 2—Electric High Lift Truck Dumping Charge Cupola. The truck not only lifts the charge but, means the special arms, tilts the bucket Fig. 3—Reduction Labor Costs Cupola Charging box and Materials Handling Equipment imately the correct weight. They are then picked one the two trucks equipped with scales. The scales are thrown into action and the crane operator, assisted signals from the truck operator, quick- trims the load the exact weight needed for the proper charge. The skid box, together with the scale mounting the DIRECT truck, shown Fig. the proper time the truck conveys the weighed charges the cupola, elevates them charging height, dumps and returns the empty box skids the filling line. The actual charging shown Fig. the spe- cial arms engaging lugs the back the skid raising the shown the photograph. Savings Shown Graphically The chart Fig. shows graphically from two different standpoints the savings accomplished this operation. The figures the left show the reduction labor costs per charge. The cost 69.2c. per charge under the former method was cut 34.2c. employ- Former Electric Including Both f ¥ The Iron Age, June 19, | 4 g 7 ing the method just described. The savings, there- fore, were almost exactly half the cost under the former method. The new cost 34.2c., should noted, includes the truck operator 60c. hour, helper 55c. hour, and charge 40c. hour for the truck itself. This charge 40c. hour for the truck includes all maintenance and power costs, secured from ac- tual record, and further includes arbitrary depre- ciation charge figured the basis fully depreciat- ing the truck three years. With such basis depreciation will seen that the figure 40c. hour arbitrarily high, since more than double this life three years has already been secured. the chart comparison Savings dif- ferent basis. observed, the for- mer direct labor cost per ton metal the spout was 47.6c. This included all handling labor prior to, well actual charging. Following the in- stallation the crane and the truck the cost per ton the spout was reduced from 47.6c. the previ- ous figures, the new cost includes fixed charges cover the crane and the truck. The total saving direct labor alone secured this method the first year has been conservatively figured the manage- ment $1,613.50. Last year amounted consid- erably over $2,000. Objections Overcome and Indirect Savings Made Link-Belt engineers studied carefully the effect the cupola charging electric truck, question had arisen regard the even distribution the charge. They find, however, that this theoretical ob- jection unsound, and they have had years satis- factory results from electric truck charging. Not only have they effected saving the direct cost charging, but the satisfaction the employees en- Cost Hand-Charging Method Weight Direct Labor Cost Pig iron 1,100 lb. $0.256 Scrap 1,900 0.410 Coke 300 0.026 Total 3,300 $0.692 Iron Age, June 19, 1930 Fig. 4—Electric Truck Handling Small Parts Through Production Department gaged this work indirect value. also interest note that the maintenance the cupolas much less now, although was thought, advance actual experience, that there might some increase the cost keeping cupolas condition. Entirely Different Problem Successfully Solved the nature its work, the Chicago plant the company requires considerable yard stor- age. Yard storage involves three distinct problems: First, shall the entire area served crane and, so, how many cranes will have used provide prompt service? Second, how material moved areas not served the crane, found too ex- pensive cover the entire yard ment? Third, shall special gang men maintained for yard handling, shall men taken ductive work when necessary? was found this case that certain part the production re- quired, without doubt, the use crane, but that, the same time, those pieces abso- lutely requiring service could stored comparative- tion the total yard area. careful check-up further indicated that the handling for which the crane was not required was spasmodic nature, but the same time necessitated using men for hr. study revealed that approximately man- hours week were involved this type handling, cost $35. perform this work, men were taken from their regular productive tasks and used push narrow-gage cars and other handling about the yards. Using Trucks and Crane Conjunction the business this concern increased, was found more and more necessary keep men their regularly assigned tasks. The solution the three problems was therefore found, first, the em- ployment one electric truck the tractor type replace the men pushing and pulling material about the yard; second, one electric truck the crane type supplement the regular crane the areas not served and, third, the employment regular crane which could limited small portion the yard area. The tractor now takes care all the work formerly handled narrow-gage cars and, since not tied down operation tracks, also performs 5 ay large amount handling and between the various build- ings, particularly moving heavy castings. spite the large sav- ings and formance the cupola-charg- ing trucks, engineers the company have found that the largest return the invest- ment comes from the employ- ment the electric crane- truck. This truck run the same operator employed the yard crane. di- vides his time equally between the two types equipment. Counting interest in- vestment, depreciation, main- tenance and the operator’s wages, this supplementary crane service costs only $40 week. Not only does the crane-truck pay for itself direct labor saved, but also indirect value open- ing large amount greatly needed storage area, and relieving the conges- tion which formerly existed the portion the stor- age area served the yard crane (see Figs. and 6). used inside the buildings also, notably the. garage building, and provides crane and transpor- tation service any part the yard buildings needed. Annual net savings resulting from the use all these electric trucks different types estimated Link-Belt Co. be, conservatively, per cent the investment. Not small part this satisfactory record comes from the application all-important motto materials handling: “The right equipment for the right job.” Tight Rivets new method riveting joints heavy plates which must withstand water steam pressure has been developed the Skoda works, and described Alois Hlava Zeitschrift des Vereines deutscher Ingenieure, Jan. 25, 1930, page 119. The rivet itself merely piece round bar correct diameter for snug fit, cut square each end, and without heads any kind. After this pin heated descaled, thrust through the hole that equal amount protrudes both sides the joint. Special snaps are attached each jaw the riveting yoke. constructed that the first pressure exerted hollow nose surrounding the rivet. This Fig. 5—Electric Crane-Truck Loading Heavy Parts Motor Truck squeezes the plates together with specified pressure. Dies then approach the pin from both ends simul- taneously, accurately centering the pin, that exactly the same sized head will formed each side the joint. The first pressure tends upset the shank and fill the hole. The continued squeeze forms the two heads, without trapping any scale under the latter. said that per cent the rivets driven this manner are steam tight and require caulking. The amount tool steel required for the dies for rivets about lb. The actual riveting may done water, oil air pressure, and the bars for the rivets, the rivet pins, are cut convenience the shop itself. Fig. Crane-Truck Performing Storage Operation Formerly Requiring the Use Yard Crane The Iron Age, June 19, Making Wrought Iron =. an ECHANICAL puddling, whereby pig iron turned into wrought iron with minimum manual effort, under commercial operation the plant the Wrought Iron Co. America Lebanon, Pa. There are six Ely rotating furnaces this plant, which four are engaged puddling and two bushelling iron products. The puddle ball, weighing 700 dumped from the furnace directly into conveyor car which delivers the press. Much time the operation puddling saved melting the pig iron oil-fired air furnace, whence taken 700-lb. installments ladle and poured into the rotary furnace. Each such charge weighed means scale the electric overhead traveling crane handling the ladle metal. The rotary furnace turned into proper position for receiving the charge, its door opened and the iron passes the usual manner. The iron this time has temperature just high enough can poured without skull the ladle. Manipulation Metal Furnace All the operations within the rotary furnace are similar their general character those involved hand-puddling, except that the melting takes place elsewhere, described. The heat cleared the Iron Age, June 19, 1930 cally Balls usual manner, roll scale other iron oxide then added, the boil takes place the usual way, and the material the proper stage its progress caused ball into coherent mass. Operation the furnace, either oscillating rotating, keeps the charge continual agitation. This manipulation greatly aided the construction the door. believed the company that the mixing the charge thus receives more uniform than proper stage the heat the door opened small crack, that cinder may drained out without losing any the iron itself, except, course, such contained chemical combination the cinder. This door-operating mechanism ingenious and permits very close control and covered the Ely patents. Incidentally, should the door refrac- tories not make tight joint with the lining the furnace, any incidental crack between them patched throwing wet ore plug the hole. This has the advantage that nothing deleterious gets into the iron process. Each heat the rotary furnace requires approxi- mately min. the end this time the ball completely ready for further processing. The furnace — Cc 4 k a — = turned over and the door opened, permitting the ball and much the cinder remaining the furnace drop.out upon inclined grating. Thence the ball goes into transfer car waiting receive it. Forming the Bloom for Rolling This takes the hydraulic press, where first the form the bloom made horizontally, establish- ing its length and width, whereupon the upper ram the press descends and crushes the mass vertically into the final bloom form. All the surfaces pressing against the metal this period have slits through which any excess cinder remaining may find its exit box below. Discharged from the hydraulic press, the bloom carried chain conveyor the first pass the muck bar rolls. These are the usual three-high type, with two sets rolls side side, and driven Corliss engine adjoining room. Successive passages the bloom through the mill reduce the final muck bar dimensions, where- upon runs out upon cooling bed. Eventually sheared into convenient lengths for handling through the finishing mills, for direct shipment outside customers, such its destination. Each heat, rep- resenting single bloom rolled out the mill, kept separate pile sheared bars until the final labo- ratory report, attesting both chemical and physical properties, has been received. Make Much Larger Units planned increase the size ball 1000 possibly little better. The the bottle” the moment lies the hydraulic press. New dies are about ready installed here, however, which will permit lengthening the bloom while retaining the present cross-sectional dimensions. OUR Rotary Ely Furnaces Operation. (Below). trouble reported other group furnaces similarly arranged. the dim background upper left will seen one the waste-heat boilers from the dies the hy- draulic press. These are contact with the incan- descent mass metal for Charging Rotary Furnace (opposite page), the Cover Plate Drawn Back and the Ladle Poured from the Crane. The scale which the charge matter only few seconds time—practically never reaching minute. They are cooled after each bloom has passed through and are said require very infrequent renewal. Both the air furnace and the rotary puddling fur- naces discharge their products combustion through waste-heat boilers, thus conserving large part the fuel cost which otherwise would have gone the stack. Enough steam generated this means run the puddling department, including its turbo- generator plant, and earn additional credits for steam furnished other departments. All the operations making muck bar this process take place building one high story, measuring 148 243 ft., with extension 120 ft. accommodating the hot bed and shears. single crane serves the main building, handling iron and other materials may needed, with auxiliary cranes the lean-to either side the main runway. The product the puddling department when fin- ished represents the first stage the manufacture. The muck bar produced now ready for the finish- ing mills, where rolled products are produced meet the requirements shape and length, and have the necessary chemical and physical qualities meet the specifications. Rolling Mills and Bolt Factories mills are the usual type, designed the various forms material offered for rolling. They consist 8-in., 9-in., and 16-in. mills with full complement furnaces, waste-heat boilers, shears, warehouses and shipping facilities. The product these mills shipped either direct outside customers the various factory depart- ments operated the com- pany Lebanon, Pa., and Pa. Both factories are equipped make the sizes nuts and bolts, railroad spikes and rivets required weighed between crane hook and ladle The Age, June 19, [ 1816—The Iron Age, June 19, 1930 UEL Oil Enters Through the Pipe Below the Man’s Elbow. (Left) Rotating the furnace operated the controller hand. The mechanism operating the door appears extreme right, the motor being mounted upon the device UDDLE Ball the Press Prior Descent the Vertical Ram. (Next Page). The length and width the bloom have been made and only the vertical dimension remains adjusted before goes the rolls the Muck-Bar Rolls the Bloom Makes Three Four Passes the Three-High Stand. (Below) stand beyond the left picture and operated from the same engine. The engine room behind the brick wall right ~ 2s 4 the trade and are now producing them all grades iron well steel. galvanizing plant which has the new fea- ture using electric current for melt- ing the spelter has been installed, and one the very few plants equipped. Inter-department service Lebanon the usual ironworks type and em- bodies broad-gage and narrow-gage rail- road equipment, augmented gasoline tractors. Shipments outside custom- ers are the usual standard-gage rail- road cars, some cases special despatch certain destinations, and motor truck local customers. Official figures for iron products for 1928 (the latest published) show that about 500,000 tons for that year was classed iron. this total 140,000 tons was wrought iron pipe, and the re- mainder was distributed between double- refined iron and common iron. The com- pany estimates that approximately 100,- 000 tons the former may sold, divided into staybolt iron 30,000 tons annually, engine bolt iron 60,000 tons and genuine iron rivets 10,000 tons. these markets the company hopes take strong position, due the lower costs (compared with hand pud- dling) and greater uniformity the mechanically puddled iron. The com- mon iron demand may placed ap- proximately 250,000 tons made the various processes re-working scrap. the total capacity such scrap- working mills the United States much above the demand, all the prod- ucts are highly competitive. French Foundry Uses Rotatin OTATING furnaces, usually electrically heated, are frequently observed American brass foundries. The same style furnace has been applied the melting other metals, especially Germany. Capacities range tons per heat. Performance such German furnace French iron foundry described Révue Fonderie Moderne, Dec. 10, 1929. This furnace consists iron cylindrical drum placed horizontally rollers, capable being rotated its hori- zontal axis, and lined internally with refractory material. The fuel usually crude petroleum supplied under pres- sure jet burner, but the one described our French contemporary fired with pulverized coal with oil feed auxiliary. Results are said highly satisfactory both technically and economically, and show marked ad- vantages over other methods fusion. charge five tons cast iron may melted from cold hr. with the attention only one workman, except the start. Fuel consumption per cent, the coal has heating value 7200 calories per kilogram (12,960 B.t.u. lb.). Fuel consumption, how- ever, not the most important factor, the principal advan- tage claimed being the negligible pickup sulphur and carbon, loss silicon manganese between the molten —_ re iL d 7 Furnace Melt Pig Iron iron and that constituting the charge. This fact enables the founder obtain with certainty precisely the chemical quality metal desired. and Steel Industry Handbook and Directory” (published Louis Cassier Co., London, England, shillings) contains many items information besides the names and addresses British iron and works and foundries. Various sections, aggregating 175 in. pages, discuss the various raw materials and operations the course manufacture, quote typical analyses the fuels, ores, and pig irons, and give illustrative data furnace charges, temperatures and other operating The general catalog the steel products the Longwy plant, Mont-Saint-Martin, France, contains 698 10%-in. pages, and bound limp leather. not only describes the products the company (steel sections detail), but takes metallurgical phases the work and technical matters, including engineering and many forms structure, such boilers, tanks, pipe joints, sheet metal construction, which the company’s product the raw material. The Iron Age, June 19, 1930—1817 | 7 = 1 7 Welding Revolutionizes Manufacturing Shears, Punches, Rolls and Welding Equipment Used Make Grinding Machine Parts—Construction Results Saving Weight AMMER mills for pulverizing and shredding various organic materials—shells, seeds, feeds, bone and the like—throw definite and exacting demands the materials which they are con- structed. Operating very high speeds (on the order 3600 r.p.m.), the rotating balance must good, the shaft alinement perfect, and the frame rigid enough prevent undue vibration. Cast iron mas- sive bases and might assumed the preferred material for such uses, indeed was years gone by. But the desire save weight—which also means freight and installation still improve the machine led the Bauer Brothers Co. Springfield, Ohio, utilize welded steel the equip- ment manufacturing such extent that gray iron foundry 130 ft. floor area has been converted largely into warehouse. shown the accompanying illustrations, hammer mill contains suitable motor, brake, nest hammers within the casing, and exhaust fan, all attached single shaft, and all mounted suitable frame. The hammers are swung from hard- ened hinge rods and are properly spaced among series disks keyed the shaft. These disks, with the swing hammers, rotate inside casing; the top part, where the feed enters, volute shape, and this lined either with smooth, corrugated herringbone plates various groovings, depending the type material ground. The rapidly rotating hammers, traveling with the speed the teeth buzz saw, strike the incoming lumps they drop into the machine, violently dashing the rebound- ing particles back from the lining until the fines work their way down into the lower part the ma- chine and fall through the screen (bent into semi- circular shape) just clearing the hammer heads the bottom half their travel. Particles falling through are sucked away the fan and delivered cyclone collector and thence bins bagging machine. Such machinery obviously must tight, reduce the dust nuisance (and even explosion hazard) and such design that can readily opened for chang- 1818—The Iron Age, June 19, 1930 ing screens different perforations when the feed changed, and for renewal worn linings hammers. These requirements, together with the strength, rigid- ity and toughness already mentioned, are secured welding the parts together into major units, which are later assembled with minimum bolts. The base the largest single piece, and the work illustrates best advantage the economies welded construction. the first place, there wide variety the motors from different electrical manu- facturers, even machines the same horsepower; consequently the size and elevation the raised por- tion the bed plate frequently changed. But with welded construction this causes great bother—the sizes the plates are merely sheared the new dimension. Four straight pieces angle iron form the lower edge-—missing corners are filled with small plates butt-welded the lower clined sides the base then are built around this frame, concealing the upstanding leg the angle which, course, furnishes added stiffness. (Rather than make re-entrant shear and have waste scrap, the side plates are two pieces with small vertical weld their butting edges.) Internal diaphragms Welded Steel Construction Combines Rigidity With Light, Dust-Tight Construction “= | are also employed give support the flat top. When welding was first utilized for these bases, the square steel plates, acting pads for the motor and mill feet were welded the bases and then ma- chined the correct height. Experience, however, has proved that the planing operation unnecessary the pads are bolted the fixtures shown the view and welded the bases while attached this jig. When the jig removed the motor and mill will line these pads without any further work being necessary. This jig not applicable all motors, however, and where odd sizes and shapes are necessary the mill and motor are bolted the pads, placed the base alinement and the pads then welded the bases. interesting note that these bases are equally strong enough and rigid enough withstand any accident dropping bumping shipment without any danger breaking and reality are claimed stronger than cast iron bases twice their own weight. Next importance the bottom casing for the hammer mill. built only nine parts, two which are steel castings. Steel castings are used for the side frames because the fact that steel plates can easily welded lugs provided them (thus simplifying jigging) and also because the interior surface must have various bosses reduce clearances the side the hammers—bosses which, made solid plate welded on, would increase the weight unduly. The welder shown completing assembled case. will noted that the side frames are merely placed the fixture, and tight locating pins are dropped through the holes the feet. The wind box sides, top and curved bottom are then dropped into place, being held ribs the casting, welded on, and, last, the flat side tacked and welded along the vertical edges. The circular groove the side frames machined (using clever welded boring mill fixture) the bent screen will slide and out readily for cleaning inter- changing with others another sized opening. The upper part the hammer housing also completely welded steel plate. hinged the front side may tipped over, uncov- ering the hammer nest, far enough the clear the lower screen can slipped out from its housing. OWER Casing Made Two Steel Castings, Two in. Bars and Five Pieces Sheared Plate. Simple jig, locating lugs and tapered pins hold assembly correct shape during welding The Iron Age, June 19, 1930—1819 > ps 7 4 The only bolts rivets used this part are those holding the liner plates place. Another interesting detail the brake, shown the general view, mounted the shaft coupling. after power off, unless braked, and custom mills, where changes feed are frequent, this represents too much lost time.) The brake drum and band are standard for Chevrolet trucks. The drum welded the coupling flange, and the band and lever are sup- ported steel plate diaphragm welded the main base. PPER Cas- Together and Inside >| 4 fey | Bottom ) A 3 Elevat Section Throuvah Hammer ECTIONAL End Elevation Hammer Mill. Coarse feed slides down chute into top casing and thrown back and forth between rotating hammers and dash plates until pulverized sufficiently fall through screen openings, from whence drawn fan, blown cyclone collector, and delivered storage bin 1820—The Iron Age, June 19, 1930 ASE Plate Made Plates and Angles. Jig used shown top page 1819 hold bearing pads cor- rect location and level, and thus eliminate all finish machining Fan cases are entirely welded the outside, al- though the necessities renewing liners require bolted assembly for certain materials. Fan impellers are ordinarily cast, due the remaining prejudice against welding any rapidly rotating part. How- ever, some very superior fans have been constructed tubing and hard steel plate—giving toughness where toughness needed, and wear resistance where the scouring action the feed felt. Such com- (Concluded page 1868) a * Heat Treating Alloy Steel Castings —Three Methods Used ALBERT RYS* EGINNING the last decade teenth century, the rise alloy steels castings rather slowly. many cases probable that the use alloys was hindered lack knowledge what results might attained doing. compositions. bon steels. General Advantages Alloy these steels. Castings most outstanding ad- vantage alloy steels their higher resistance shock (i.e. impact value) and high-tensile strength and elastic limit. This particularly true the chromium-nickel group. Other points superiority that may included general way are higher strength elevated temperatures, and greater re- sistance wear and repeated stresses. Magnetic and electrical properties may varied within wide limits suitable adjustment the composition the steels. For example require- ments for high resistivity are met the per cent nickel, per cent chromium alloy. High retentivity exhibited chromium steel containing per cent cobalt, while very low permeability may ob- tained either the per cent nickel per cent manganese steels. Chemical properties alloy steels are becoming increasing importance. Resistance corrosion dilute sulphuric acid and sea water shown the V2A steels noteworthy. Oxidation high tem- peratures (scaling reduced alloying steel with aluminum, chromium nickel-chromium. Proper Heat Treatment Gives Best Results EXT the correct composition, the most impor- tant factor securing best results from alloy steels proper heat treatment. This chiefly dis- tinguished from that required for carbon steels that low rate cooling permitted owing the sluggishness the transformations. this ac- count also these materials are amenable normal- izing throughout and development the highest tensile and impact strengths. *Essen, Germany. Abstracted from the foundry issue und Eisen, No. 50, 1930, pages 423 438, Gaines, Jr., Cambridge, Mass. AGNETIC and electrical prop- erties may varied within wide limits suitably changing the Pronounced differences cooling air oil with Cr-Ni alloys—slight differences with car- Increasing importance being at- tributed the chemical properties Three different ways heat treat produce varying properties. quenching carbon steels, where very rapid cooling necessary, possible properties which depend rapid cooling only the sur- face the piece. With alloy steels such the 4.5 per cent nickel, 1.5 chromium, the other hand, large sections may cooled air—i.e., relatively slowly —and the effect heat treat- ment will nearly uniform throughout. Although abounds with experimental data alloy steels, far the larger part deals with forged material. applying such data cast- ings, necessary remember that the properties the forged specimens are due both hot work and heat treatment, whereas cast steel may improved only the latter manner. from Series Steels Used Experiments order ascertain certain general principles applied making alloy castings, series steels was made the Krupp Laboratories and cast into test pieces. From these pieces samples were cut having cross-sections 40, 80, 120, 200, and 400 sq. mm. The composition the steels given the table, together with the temperature which each was heated. Three Different Methods Heat Treating Each section each alloy was treated three different ways: No. Air-cooled; normalized and annealed 600 deg. No. Quenched oil. No. Heated hr. 1000 deg. C., cooled furnace 300 deg. C., reheated and quenched oil. preliminary examination was made the ap- pearance the fracture the mm. and the 400 mm. sections before treatment, after treatment No. and after No. was observed that even the air normalizing was sufficient all cases effect substantial refinement the grain. Further treatment increased the refinement, the best struc- tures being noted the mm. section after treat- ment No. This appeared identical with the structure forged steel similar composition and history. The structures the high carbon (A) The Iron Age, June 19, 1930—1821 7 7 and vanadium (N) steels were Table Composition the Cast Steels Selected minimum Tem- For sections larger best being steel 0.58 0.75 850 that the tion the various speci- 2.01 (G) show marked advan- mens confirmed the con- tages over carbon steels, clusions drawn from the due the fact that the appearance the frac- 0.10 0.51 inevitable slow cooling tures. The difference pro- the central portion duced cooling air 0.60 890 the casting still suffi- oil was slight the case the carbon steels, most pronounced the case the chromium-nickel alloys. Physical properties were found accord excel- lently with expectations from the microstructures. Air-cooling produced with the unalloyed steels slight improvement elastic limit, ultimate strength, elongation, and Charpy impact value. Further in- creases, though not large, were brought out the oil treatment. Chromium-nickel steel (G), when tested before treatment, broke slightly above the elastic limit—at about kg. per sq. mm. (55,000 per sq. in.). After the air oil treatments, the elastic limit increased kg. per sq. mm. and the tensile strength kg. per sq. mm. Elongation and impact value increased several hun- dred per cent. Tensile and Impact Values Compared interesting comparison afforded between steels approximately equal carbon contents (0.19- 0.24 per cent) their relative strengths. The highest tensile strength and lowest impact strength are given the vanadium alloy (N). The values (taken from charts the original paper and hence not exact) are given the table below: {Mn E lim., 37 47 37 $2 §2 71 69 I 12 15 14 The data given apply only the mm. section (40 mm. about 1.6 in.), and remarked that the vanadium steel castings not show such high tensile properties larger sections. The Cr- alloys show nearly high strength larger sections and not exhibit the disadvantage brittleness. Further comparison possible between steels having the same approximate tensile strength (70-80 kg. per sq. mm.) and section mm. square. Con- sidering the elastic limit and impact values, the most favorable properties are shown Cr-Ni steel (G) and slightly lower degree the Cr-Mo steel (M), which, oil hardening especially, shows good elongation (11 kg. per sq. cm.) and favor- able elastic limit (52 kg. per sq. mm.). Carbon (A) and vanadium (N) steels show very low impact values. Alloy steels offer the builder and designer the advantage high strength combined with 1822—The Iron Age, June 19, 1930 ciently rapid outdis- tance the sluggish transformation reactions the alloy. The effect increasing the section the tens